Mitsubishi Outlander GS45X. Manual - part 1546

BASIC BRAKE SYSTEM DIAGNOSIS

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BASIC BRAKE

35A-13

STEP 8. Adjust the brake pedal.
Refer to 

P.35A-15

.

Q: Is the brake pedal adjusted correctly?

YES : Go to Step 9.
NO :  Adjust the brake pedal. Then go to Step 9.

STEP 9. Recheck symptom.
Q: Is the symptom eliminated?

YES : The procedure is complete.
NO :  Start over at step 1. If a new symptom surfaces, refer 

to the symptom chart.

INSPECTION PROCEDURE 8: Groaning, Clicking or Rattling Noise when Brakes are not Applied.

DIAGNOSIS

.

STEP 1. Check whether foreign material has entered the 
wheel covers.
Q: Is there any foreign material?

YES : Remove it. Then go to Step 5.
NO :  Go to Step 2.

STEP 2. Check for looseness of the wheel nuts.
Q: Are the wheel nuts loose?

YES : Tighten to 98 

± 10 N⋅m (73 ± 7 ft-lb). Then go to Step 

5.

NO :  Go to Step 3.

BASIC BRAKE SYSTEM DIAGNOSIS

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BASIC BRAKE

35A-14

STEP 3. Check for looseness of the caliper installation 
bolt.
Q: Is the caliper installation bolt loose?

YES : Tighten to 100 

± 10 N⋅m (74 ± 7 ft-lb) for the front 

caliper. Tighten to 55 

± 5 N⋅m (41 ± 3 ft-lb) <2.4L 

Engine: 5 persons seat> or 58 

± 7 N⋅m (43 ± 5 ft-lb) 

<2.4L Engine: 7 persons seat, 3.0L Engine> for the 
rear caliper. Then go to Step 5.

NO :  Go to Step 4.

STEP 4. Check the wheel bearings for end play.
Refer to GROUP 26 

− On-vehicle Service, Wheel bearing end 

play check 

P.26-11

 <Front>, GROUP 27A 

− On-vehicle Ser-

vice, Wheel bearing end play check 

P.27A-6

 <Rear (FWD)> or 

GROUP 27B 

− On-vehicle Service, Wheel bearing end play 

check 

P.27B-17

 <Rear (AWD)>.

Q: Does the measured end play exceed the limit?

YES : Replace the faulty hub assembly. Then go to Step 5.
NO :  Go to Step 5.

STEP 5. Recheck symptom.
Q: Is the symptom eliminated?

YES : The procedure is complete.
NO :  Start over at step 1. If a new symptom surfaces, refer 

to the symptom chart.

AC610134

<Front>

AB

AC610135

<Rear>

AB

SPECIAL TOOLS

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BASIC BRAKE

35A-15

SPECIAL TOOLS

M1352000601548

ON-VEHICLE SERVICE

BRAKE PEDAL INSPECTION

M1351003500793

CAUTION

Do not apply grease or lubricant to the switch and the 
switch installation section to avoid malfunction of the 
switch. In addition, do not use gloves which have grease 
on them.

.

BRAKE PEDAL HEIGHT CHECK

1. Turn up the floor carpet under the brake pedal.
2. Remove the stoplight switch (Refer to 

P.35A-28

).

3. Use a needle or similar tool to measure the dimension A in 

the figure (distance from the dash panel pad surface to the 
dash panel).

4. Measure the dimension B in the figure (distance from the 

pedal pad surface to the dash panel pad surface).

5. Make sure that the total of the dimensions A and B 

measured in Steps 2 and 3 (brake pedal height) is within the 
standard value.

Standard value (A+B): 221.8 

− 227.8 mm (8.7 − 9.0 inch)

6. When the brake pedal height is not within the standard 

value, inspect the brake pedal in the following procedure.

(1) Remove the brake pedal assembly (Refer to 

P.35A-28

).

(2) Check the removed brake pedal assembly for distortion, 

and replace it when deformed (Refer to 

P.35A-29

).

(3) Install the brake pedal assembly (Refer to 

P.35A-28

).

NOTE: When installing, compress the dash panel pad.

Tool

Number

Name

Use

MB992146

Booster test 
adapter

Inspection using a simplified tester

MB990964

A: MB990520

Brake tool set
A: Piston expander

Disk brake piston pushing back

MB992146

MB990964

A

B

AC505506AE

B

A

Dash panel

Dash panel pad

Stoplight
switch

ON-VEHICLE SERVICE

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BASIC BRAKE

35A-16

(4) Measure the brake pedal height again, and make sure 

that it is within the standard value (A+B).

 

When the measured value is not within the standard 
value, measure the dimension C in the figure (distance 
from the stud bolt end to the clevis hole center), and 
make sure it is within the standard value (C).

Standard value (C): 75.8 

− 80.2 mm (2.98 − 3.16 inch)

(5) When the measured value is not within the standard 

value (C), replace the brake booster (Refer to 

P.35A-30

).

7. After checking the brake pedal height, install the stoplight 

switch in the following procedure:

(1) Screw in the stoplight switch until its thread contacts the 

pedal stopper, then turn the switch approximately one 
eighth of a clockwise turn to fix it. While doing this, pull 
and hold the brake pedal by hand.

(2) Check that the clearance between the stoplight switch 

and the pedal stopper is as shown in the figure.

CAUTION

Make sure that the stoplight is not illuminated when the 
brake pedal is not depressed.

(3) Connect the stoplight switch connector.

8. Check the key interlock mechanism and the shift lock 

mechanism (Refer to GROUP 23A 

− On-vehicle Service, 

Key Interlock Mechanism Check 

P.23A-149

, Shift Lock 

Mechanism Check 

P.23A-151

).

9. Recover the floor carpet under the brake pedal.

.

AC508163AB

C

Clevis

Stud bolt

AC309282 AG

0.5 to 1.5 mm
(0.02 to 0.06 in)

Pedal stopper

Pedal stopper

Stoplight switch